Packaging container and method

ABSTRACT

A packaging container includes a pallet, an enclosure box, an enclosure base, a sheet, and a set of fasteners. The pallet carries the article thereon. The enclosure box rests on the pallet to enclose the article therewithin, and includes a top wall, first and second pairs of opposite side walls, an open bottom, and a first set of through-holes. The enclosure base lies between the article and the pallet to hold the article. The sheet extends across at least a portion of the pallet and the first pair of opposite side walls to secure the pallet to the enclosure box when fastened to the enclosure box, and includes a flat center panel, a pair of side flaps, and a second set of through-holes. The set of fasteners are passed through the first and second sets of through-holes to fasten the sheet to the enclosure box from outside the enclosure box.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent application claims priority pursuant to 35 U.S.C.§119 from Japanese Patent Application No. 2008-085411, filed on Mar. 28,2008, the contents of which are hereby incorporated by reference hereinin their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a packaging container and method, andmore particularly, to a packaging container using a pallet and enclosurebox to package an article for storage and transport, and a method forpackaging an article in such a container.

2. Discussion of the Background

Shipping containers are used to package large electronic equipment suchas printers and copiers for storage and transport. A typical design ofsuch containers includes an upper enclosure box to enclose an articletherewithin, and a lower platform or pallet having an open-sided hollowstructure to accommodate tines of a forklift during handling of thecontainer. The enclosure box is made of corrugated cardboard with thepallet formed of wood or plywood for strength and durability, whilecardboard pallets are often used depending on specific applications.

In most such containers, the pallet and enclosure box are secured toeach other to form an integrated structure which prevents shifting ofpackaged articles during handling of the shipping container. To providesafe and efficient packaging of articles, various methods have beenproposed to reliably secure an enclosure box to a pallet in anintegrated pallet container.

For example, one conventional packaging container secures an enclosurebox onto a pallet by passing a pair of straps around the enclosure boxthrough side openings in the hollow pallet, and tightening the strapswith a buckle or fastener connecting opposite ends of each encirclingstrap.

Another conventional packaging container includes a corrugated cardboardpallet having through-holes in its sides in addition to side openings toaccommodate forklift tines, and an enclosure box having correspondingthrough-holes on sides near the bottom edge. In this packagingcontainer, the enclosure box is secured to the pallet by engagingattachments in the corresponding through-holes of the pallet and theenclosure box.

One drawback of the securing technique using fastening straps is thatthe need for strapping the enclosure box and pallet makes it troublesometo assemble the container, and that handling the assembled container candamage the enclosure box where concentrated stresses are applied tothose corners that are in contact with the encircling straps.

On the other hand, the packaging container having the pallet andenclosure box secured by corresponding through-holes is relatively easyto assemble, but requires the use of cardboard pallets rather thanstandard wood or plywood pallets, limiting practical application of thismethod to pallet containers integrally made of corrugated cardboard.

SUMMARY OF THE INVENTION

Exemplary aspects of the present invention are put forward in view ofthe above-described circumstances, and provide a novel packagingcontainer using a pallet and enclosure box to package an article forstorage and transport.

Other exemplary aspects of the present invention provide a novel methodfor packaging an article in a container using a pallet and enclosure boxfor storage and transport.

In one exemplary embodiment, the novel packaging container includes apallet, an enclosure box, an enclosure base, a sheet, and a set offasteners. The pallet is substantially rectangular in plan, and carriesthe article thereon. The enclosure box rests on the pallet to enclosethe article therewithin, and includes a top wall, first and second pairsof opposite side walls, an open bottom, and a first set ofthrough-holes. The top wall covers a top of the article. The first andsecond pairs of opposite side walls extend downward from the top wall tocover sides of the article. The open bottom is defined by edges of theside walls in contact with the pallet to pass the article therethroughduring assembly. The first set of through-holes are defined in the firstpair of side walls adjacent to the open bottom. The enclosure base liesbetween the article and the pallet to hold the article within theenclosure box. The sheet extends across at least a portion of the palletand the first pair of opposite side walls to secure the pallet to theenclosure box when fastened to the enclosure box, and includes a flatcenter panel, a pair of side flaps, and a second set of through-holes.The flat center panel underlies the portion of the pallet. The pair ofside flaps extends from opposite sides of the center panel upward alongthe first pair of opposite side walls beyond the first set ofthrough-holes. The second set of through-holes is defined in the pair ofside flaps to align with the first set of through-holes. The set offasteners is passed through the first and second sets of through-holesto fasten the sheet to the enclosure box from outside the enclosure box.

In one exemplary embodiment, the packaging method includes the steps ofpallet provision, base provision, article placement, box placement,sheet placement, and sheet fastening. The pallet provision step providesa pallet substantially rectangular in plan. The base provision stepprovides an enclosure base on the pallet. The article placement placesan article on the enclosure base. The box placement places an enclosurebox on the pallet to enclose the article and the enclosure basetherewithin. The enclosure box includes a top wall, first and secondpairs of opposite side walls, an open bottom, and a first set ofthrough-holes. The top wall covers a top of the article. The first andsecond pairs of opposite side walls extend downward from the top wall tocover sides of the article. The open bottom is defined by edges of theside walls in contact with the pallet to pass the article therethrough.The first set of through-holes are defined in the first pair of sidewalls adjacent to the open bottom. The sheet placement places a sheetacross at least a portion of the pallet and the first pair of oppositeside walls. The sheet includes a flat center panel, a pair of sideflaps, and a second set of through-holes. The flat center panelunderlies the portion of the pallet. The pair of side flaps extends fromopposite sides of the center panel upward along the first pair ofopposite side walls beyond the first set of through-holes. The secondset of through-holes is defined in the pair of side flaps to align withthe first set of through-holes. The sheet fastening step fastens thesheet to the enclosure box from outside the enclosure box to secure thepallet to the enclosure box by passing a set of fasteners through thefirst and second sets of through-holes.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the disclosure and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is an assembled view schematically illustrating a packagingcontainer according to one embodiment of this patent specification;

FIG. 2 is an exploded perspective views schematically illustrating thepackaging container of FIG. 1;

FIGS. 3A through 3D are top, front, side, and bottom views,respectively, and FIGS. 3E and 3F are cross-sectional views taken alongline E-E and line F-F, respectively, of FIG. 3A, schematicallyillustrating a pallet included in the packaging container of FIG. 1;

FIG. 4 is a plan view schematically illustrating an example of anenclosure base included in the packaging container of FIG. 1;

FIG. 5 is a perspective view schematically illustrating the enclosurebase of FIG. 4;

FIG. 6 is a plan view schematically illustrating an example of a sheetincluded in the packaging container of FIG. 1;

FIG. 7 schematically illustrates an example of a fastener for use in thepackaging container of FIG. 1;

FIGS. 8A through 8C are cross-sectional views schematically illustratingthe fastener of FIG. 7 in use;

FIG. 9 is an exploded perspective view schematically illustrating apackaging container according to another embodiment of this patentspecification;

FIG. 10 is a partially exploded perspective view schematicallyillustrating a packaging container according to yet another embodimentof this patent specification; and

FIG. 11 is a partial perspective view schematically illustrating apackaging container according to still another embodiment of this patentspecification.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In describing exemplary embodiments illustrated in the drawings,specific terminology is employed for the sake of clarity. However, thedisclosure of this patent specification is not intended to be limited tothe specific terminology so selected, and it is to be understood thateach specific element includes all technical equivalents that operate ina similar manner and achieve a similar result.

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, exemplaryembodiments of the present patent application are described.

FIGS. 1 and 2 are assembled and exploded perspective views,respectively, schematically illustrating a packaging container 100according to one embodiment of this patent specification.

As shown in FIGS. 1 and 2, the container 100 includes a pallet 110, anopen-ended enclosure box 120, an enclosure base 130, a sheet 140, a setof fasteners 150, and eight corner pads 160, all of which are assembledinto an integrated structure for packaging an article 10, for example, aprinter, for storage or transport.

In the container 100, the pallet 110 is substantially rectangular inplan and lies at the bottom to place the article 10 thereon. Theenclosure box 120 rests on the pallet 110 to enclose the article 10placed on the pallet 110, and the enclosure base 130 lies between thearticle 10 and the pallet 110 to hold the article 10 within theenclosure box 120. The sheet 140 extends across a width of the pallet110 while fastened to the enclosure box 120 with the fasteners 150,thereby securing the pallet 110 to the enclosure box 120.

FIGS. 3A through 3D are top, front, side, and bottom views,respectively, and FIGS. 3E and 3F are cross-sectional views taken alongline E-E and line F-F, respectively, of FIG. 3A, schematicallyillustrating the pallet 110 included in the packaging container 100 ofFIGS. 1 and 2.

As shown in FIGS. 3A through 3F, the pallet 110 includes a pair ofparallel stringers 111, a pair of parallel top deckboards 112 overlyingthe stringers 111 with a gap 115 therebetween, a pair of parallel bottomdeckboards 113 underlying the stringers 111 with a gap therebetween, allof which are made of wood or plywood. The stringers 111 extend in atransverse-direction on opposite ends of the pallet 110, while the topand bottom deckboards 112 and 113 extend in a longitudinal directionperpendicular to the transverse direction to define an upperload-carrying surface and a lower load-bearing surface, respectively, ofthe pallet 110. The pallet 110 thus forms an open-sided hollow structurewith side openings 116 leading to an interior space 117 defined by thestringers 111 and the top and bottom deckboards 112 and 113.

With particular reference to FIGS. 3A, 3B, 3E, and 3F, the pallet 110also includes a pair of spacers 114 located on opposite ends between thetop deckboards 112 above the stringers 111. Each spacer 114 is formed ofwood or plywood, and has a width substantially equal to that of theadjoining stringer 111, a length substantially equal to that of the topdeck gap 115, and a thickness substantially equal to that of the topdeckboards 112.

In the assembled container 100, the pallet 110 supports the enclosedarticle 10 on the upper load-carrying surface, while allowing entry offorklift tines or forks into the space 117 through the side opening 116during handling and transport by a forklift. Further, the pallet 110 canprevent dust and other contaminants from entering the enclosure box 120with the top deck spacers 114 fitted into a space between the pallet 110and the enclosure box 120.

As will be described later, the pallet 110 may interlock with theenclosure base 130 by accommodating a portion of the enclosure base 130in the top deck gap 115, so as to restrict movement of the enclosurebase 130 on the underlying pallet 110. In such a configuration, formingthe deck spacer 114 and the stringer 111 of a substantially equalthickness is desirable, since it prevents the spacer 114 from projectinginward beyond the edge of the stringer 111 and urging the interlockingportion of the enclosure base 130 to interfere with proper entrance offorklift tines.

Referring back to FIG. 2, the enclosure box 120 includes an open bottom121 and a top wall 122 opposed to each other, two pairs of opposite sidewalls 123 and 124 extending vertically downward from the top wall 122 todefine the open bottom 121 at bottom edges thereof, and fourthrough-holes 127, two on each side wall 123 adjacent to the open bottom121. The enclosure box 120 is formed of corrugated cardboard, and issized to fit on the rectangular pallet 110 when installed to enclose thearticle 10 of certain dimensions.

During assembly, the enclosure box 120 is placed from above onto thepallet 110 carrying the article 10 covered and cushioned by theenclosure base 130 and the corner pads 160. Thus, the article 10together with the base 130 and the pads 160 pass through the open bottom121 to be enclosed by the top and side walls 122, 123, and 124 in theenclosure box 120.

In the assembled container 100, the enclosure box 120 has the openbottom 121 contacting the top deckboards 112 and the top deck spacers114, the top and side walls 122, 123, and 124 surrounding the article10, and the through-holes 127 positioned immediately above the palletopenings 116.

FIGS. 4 and 5 are plan and perspective views, respectively,schematically illustrating an example of the enclosure base 130 beforeand during assembly, included in the packaging container 100.

As shown in FIG. 4, the enclosure base 130 before assembly includes asubstantially rectangular center panel 131; a pair of side flaps 132extending outward from a pair of opposed parallel sides of the centerpanel 131; four openings 133, two on each side flap 132; a pair of tabs135 extending outward from another pair of opposed parallel sides of thecenter panel 131; and two pairs of narrow end flaps 137 extendingoutward from the center panel 131 on sides of the tabs 135. Alsoincluded are a pair of parallel fold lines 134 separating the centerpanel 131 from the side flaps 132, a pair of parallel, middle fold lines136 separating the center panel 131 from the tabs 135, and two pairs ofparallel fold lines 138 separating the center panel 131 from the endflaps 137. Such components of the enclosure base 130 are integrallyformed of a single flat blank of corrugated cardboard, and are properlysized to support the article 10 inside the open bottom 121 of theenclosure box 120 when folded and assembled into the integratedcontainer 100.

During assembly, the flat blank of the base 130 is folded upward alongthe fold lines 134 and 138 to raise the side flaps 132 and the end flaps137 above the center panel 131, and downward along the fold lines 136 tolower the end tabs 135 below the center panel 131. The base 130 afterfolding is placed on the top deck of the pallet 110, followed by placingthe corner pads 160 at four corners of the center panel 131.

As shown in FIG. 5, the enclosure base 130 thus installed has the centerpanel 131 overlying the top deckboards 112 with the tabs 135 insertedinto the top deck gap 115 against the top deck spacers 114, and the sideand end flaps 132 and 137 raised along the sides and ends of the pallet110 to support the corner pads 160 in place on the center panel 131.

As mentioned, the tabs 135 accommodated in the top deck gap 115 forms aninterlock to restrict movement of the enclosure base 130 on theunderlying pallet 110. The end tabs 135 are sized to project downwardbelow the top deckboards 112 only a distance sufficient to stabilize theenclosure base 130, since too large a projection into the space 117would interfere with proper insertion of the forklift tines.

With additional reference to FIGS. 1 and 2, in the assembled container100, the enclosure base 130 lies between the pallet 110 and the article10 within the enclosure box 120. With the side and end flaps 132 and 137properly aligning the lower corner pads 160 on the center panel 131, theenclosure base 130 can hold the article 10 in place within the enclosurebox 120. In addition, the side flaps 132 have the flap openings 133facing the through-holes 127 of the enclosure box 120. These openings133 are larger in size than the through-holes 127, and serve to preventthe fasteners 150 from interfering with the side flaps 132 duringinstallation.

FIG. 6 is a plan view schematically illustrating an example of the sheet140 before assembly, included in the packaging container 100.

As shown in FIG. 6, the sheet 140 includes a substantially rectangularcenter panel 141, a pair of side flaps 142 extending outward fromopposed parallel sides of the center panel 141, four through-holes 143,two on each side flap 142, and a pair of parallel fold lines 144separating the center panel 141 from the side flaps 142. Such componentsof the sheet 140 are integrally formed of a single flat blank ofcorrugated cardboard.

During assembly, the blank of the sheet 140 is inserted through the sideopening 116 into the space 117 of the pallet 110 carrying the article 10enclosed in the enclosure box 120. After insertion, the sheet 140 isfolded upward along the fold lines 144, so as to raise the side flaps142 beyond the through-holes 127 of the enclosure box 120 with thethrough-holes 143 aligned with the through-holes 127 of the enclosurewall 123 for fastening with the fasteners 150.

As shown in FIGS. 1 and 2, in the assembled container 100, the sheet 140extends across the width of the pallet 110 and the enclosure box 120.With the side flaps 142 fastened to the enclosure walls 123, the sheet140 secures the pallet 110 to the enclosure box 120. Further, the sheet140 covers the top deck gap 115 of the pallet 110 with the center panel140 from below for secure and safe handling with forklift tines.

FIG. 7 schematically illustrates an example of the fastener 150 for usein the packaging container 100.

As shown in FIG. 7, the fastener 150 is constituted of an open-endedtubular body 151 having one open end surrounded by a flange 153, and theother open end having a pair of angled plates 156, each forming an “L”in cross-section and hinged to an inner wall of the tubular body 151,and a plug 155 connected to the flange 153 via a hinge 154, all of whichare formed as a single integrated unit made of synthetic resin. Beforeuse, the fastener 150 has the plug 155 outside the tubular body 151 sothat the hinged plates 156 point their free ends in the same direction.This allows the flange-less end of the tubular body 150 to enter anopening of a particular size. Inserting the plug 155 into the tubularbody 151 causes the plates 156 to turn on their respective hinges,enabling the fastener 150 to hold together walls of a certain thicknessbetween the flange 153 and the plates 156.

FIGS. 8A through 8C are cross-sectional views schematically illustratingthe fastener 150 in use to fasten the sheet 140 to the enclosure box120.

To install the fastener 150, first, the tubular body 151 is insertedinto the aligned through-holes 143 and 127 of the sheet flap 142 and theenclosure wall 123 with the plug 155 remaining outside or partiallyinside the tubular body 151. The tubular body 151 is squeezed until theflange 153 comes into contact with the sheet flap 142 (FIG. 8A).

After inserting the tubular body 151, the plug 155 is inserted into thetubular body 151 from the flanged end toward the flange-less end (FIG.8B).

The inserted plug 155 ultimately comes into contact with the hingedplates 156 to turn them approximately 90 degrees on their respectivehinges, thereby engaging the tubular body 151 in the alignedthrough-holes 143 and 127. Thus, the fastener 150 connects together thesheet flap 142 and the box wall 123 by abutting the flange 153 againstthe sheet flap.142 at one end, and the plates 156 against the box wall123 at the other end (FIG. 8C).

To release the connection between the sheet flap 142 and the box wall123, the fastener 150 is removed by retracting the plug 155 away fromthe flange-less end of the tubular body 151, returning the hinged plates156 to their original positions, and then drawing the tubular body 151away from the through-holes 127 and 143.

Thus, the fastener 150 provides secure connection between the enclosurebox 120 and the sheet 140 through operation from outside the enclosurebox 120 without requiring special tools for installation and releasing.

Referring back to FIG. 2, the eight corner pads 160, four between theenclosure base 130 and the article 10 and four between the article 10and the box 120, are formed of plastic foam, such as expandedpolystyrene (EPS) or expanded polyethylene (EPE), and are shaped toconform to the shape of the article 10 so as to cushion and hold thearticle 10 at eight corners of the container 100.

Specifically, the lower four pads 160 prevent horizontal displacement ofthe article 10, and the upper four pads 160 prevent verticaldisplacement of the article 10. Preferably, the lower pads 160 each hasa protrusion on the bottom side and the enclosure base 130 hascorresponding recesses at the four corners, so as to anchor each pad 160to the enclosure base 130 by engaging the corresponding protrusion andrecess, which enables more reliable positioning of the pads 160 and thecushioned article 10 on the enclosure base 130.

Having described configurations of the respective elements of thepackaging container 100, the following describes procedures forpackaging the article 10 in the container 100 with particular referenceto FIG. 2.

First, the enclosure base 130 is placed on the top deck of the pallet110 with the side flaps 132 folded upward along the fold lines 134, thetabs 135 folded downward along the fold lines 136, and the end flaps 137folded upward along the fold lines 138, so that the tabs 135 fit in thegap 115 against the top deck spacers 114.

After positioning the enclosure base 130, the four corner pads 160 areplaced on the respective corners of the enclosure base 130, preferablyeach having a protrusion on the bottom to engage with a correspondingrecess formed in the enclosure base 130. Then, the article 10 is placedon the lower pads 160, followed by providing the additional four pads160 on the upper corners of the article 10.

With the article 10 thus positioned, the enclosure box 120 is placed onthe pallet 110 from above, with the open bottom 121 allowing entry ofthe article 10 into the box 120 during placement. When set in place, theenclosure box 120 has the bottom edge (i.e., the lower edges of the sideand end walls 123 and 124, or the perimeter of the open bottom 121)resting on the top deckboards 112 and the top deck spacers 114 aroundthe perimeter of the enclosure base 130.

The top deckboards 112 and the spacers 114, having a substantially equalheight, form a substantially even, planar surface maintaining continuouscontact with the box edge, which prevents damage to the box 120 bydistributing loads applied thereto, allowing for stacking of multiplecontainers, while preventing dust and other contaminants from enteringthe enclosure box 120.

After placing the enclosure box 120, the sheet 140 is inserted into thespace 117 through the opening 116, followed by folding the flaps 142upward along the fold lines 144 and bringing the center panel 141 intocontact with the top deckboards 112. The sheet 140 thus wrapping the topdeck of the pallet 110 is fastened to the enclosure box 120 by engagingthe fasteners 150 in the through-holes 143 and 127 aligned with eachother. As mentioned earlier, the enclosure base 130 inside the enclosurebox 120 does not interfere with installation of the fasteners 150 owingto the openings 133 providing clearance between the fasteners 150 andthe side flaps 132.

In the container 100 thus completed, the pallet 110 is securelyconnected to the enclosure box 120 by the sheet 140, and to theenclosure base 130 by the interlock between the tabs 135 and the topdeck gap 115. Such secure connection effectively stabilizes the enclosedarticle 10 during handling of the container 100, since the article 10 isfixed to the walls of the enclosure box 120 and the enclosure base 130by the cushioning pads 160.

The completed container 100 is ready for handling by a forklift with thepallet 110 accommodating the forklift tines in the deck space 117. Withthe enclosure base 130 and the sheet 140 sandwiching the top deck gap115, the container 100 prevents the forklift tines from accidentallysticking into the gap 115 to damage the enclosed article 10 duringhandling with a forklift.

Further, when necessary, the container 100 allows access to the enclosedarticle 10 by removing the enclosure box 120 from the pallet 110 throughthe ready and tool-less operation of the fasteners 150 as mentionedabove.

Thus, the packaging container 100 according to this patent specificationenables secure connection between the enclosure box and pallet, whichrequires no modification of an existing pallet design, while providinggood protection of the enclosure against breakage as well as ready andtool-less assembly and disassembly of the integrated container.

FIG. 9 is an exploded perspective view schematically illustrating apackaging container 200 according to another embodiment of this patentspecification.

As shown in FIG. 9, the general configuration of the container 200 issimilar to that depicted primarily in FIG. 2, except that the container200 uses a sheet 340 with additional flaps instead of the sheet 140 ofFIG. 6.

Specifically, the sheet 340 includes a substantially rectangular centerpanel 341, a pair of side flaps 342, four through-holes 343 (two each ineach of side flaps 342), and a pair of parallel fold lines, similar tothose of the sheet 140. In addition, the sheet 340 includes a pair offlaps 347 extending from another pair of opposed parallel sides of thecenter panel 341, and a pair of fold lines 346 separating the centerpanel 341 from the flaps 347.

During assembly, the blank of the sheet 340 is folded downward along thefold lines 346, so as to lower the end flaps 347 before insertion intothe deck space 117 and subsequent folding of the side flaps 342. Thefolded end flaps 347 each has a height slightly smaller than that of thespace 117, and when inserted into the space 117, has a bottom edgeresting on the bottom deckboards 113 to retain the center panel 341immediately beneath the top deckboards 112, which facilitates subsequentfastening of the sheet 340 to the enclosure box 120.

Thus, the embodiment with the downward flap 347 enables readierinstallation of the sheet 340, leading to enhanced usability of thecontainer according to this patent specification.

FIG. 10 is a partially exploded perspective view schematicallyillustrating a packaging container 400 according to yet anotherembodiment of this patent specification.

As shown in FIG. 10, the general configuration of the container 400 issimilar to that depicted primarily in FIG. 2, except that the container400 uses a triple-stringer pallet 410 and a pair of twin sheets 440instead of the pallet 110 and the sheet 140 of FIG. 2.

Specifically, the pallet 410 includes a middle stringer 412 in additionto a pair of end stringers 411, thus forming a pair of separate hollowspaces 417 on opposite sides of the middle stringer 412 between the topand bottom deckboards. The triple-stringer structure provides stiffnessto the pallet 410, which is desirable particularly where the pallet hasa substantial length over which to support a load of greater volume andweight.

In addition, the twin sheets 440 each includes a substantiallyrectangular, elongated center panel 441, a pair of side flaps 442extending from opposite ends of the center panel 441, a pair ofthrough-holes 443, one on each side flap 442, and a pair of parallelfold lines 444 separating the center panel 441 from the side flaps 443.

During assembly, each twin sheet 440 is inserted into the deck space417, and is folded upward along the fold lines 444, so as to raise theside flaps 442 beyond the through-holes 127 of the enclosure box 120with the through-holes 443 aligned with the through-holes 127 of theenclosure wall 123 for fastening with the fasteners 150.

Thus, the embodiment with the triple-stringer pallet 410 and the twinsheets 440 enables application of the container to packaging of heavy orbulky articles. Optionally, each twin sheet 440 may include additionaldownward flaps similar to those described in FIG. 9, which facilitatesinstallation of the sheet 440 into the deck space 417.

FIG. 11 is a partial perspective view schematically illustrating apackaging container 500 according to still another embodiment of thispatent specification.

As shown in FIG. 11, the general configuration of the container 500 issimilar to that depicted in FIGS. 2, 9, or 10, except that the container500 has a four-flap enclosure base 530 instead of the enclosure base 130of FIG. 5.

Specifically, the enclosure base 530 includes a substantiallyrectangular center panel 531, a pair of side flaps 532, and fourthrough-holes 533, similar to those depicted in FIG. 5. In addition, theenclosure base 530 includes a pair of integral end flaps 537 extendingoutward from the center panel 531, a pair of tabs 535 formed by cuttingout a portion of the end flap 537, and a pair of parallel, discontinuousfold lines 538 on sides of the tabs 535 separating the center panel 531from the end flaps 537.

The flat blank of the base 530 is folded upward along the fold lines 538to raise the end flaps 537 above the center panel 531. The enclosurebase 530 with the integral end flap 537 requires only a single fold toform each end wall to support the lower pads 160, whereas the enclosurebase 130 with the separate end flaps requires two folds for each endwall. Thus, the embodiment of FIG. 11 saves time in installing theenclosure base 530, while the embodiment of FIG. 5 makes it effortlessto form each end wall of the enclosure base 130 for ready assembly ofthe packaging container.

Numerous additional modifications and variations are possible in lightof the above teachings. For example, pallets used in the packagingcontainer according to this patent specification may be made ofsynthetic resin, metal, or any suitable material and may have four opensides to allow entry of forklift tines from four directions, althoughthe embodiments described herein use a two-way pallet of wood orplywood.

Further, although the enclosure box, the enclosure base, and the sheetdescribed above are formed of corrugated cardboard, alternatively thesecomponents may be formed of corrugated plastic or any other suitablematerial, and may be suitably sized and shaped depending on the intendedapplication.

Furthermore, fastening the sheet to the enclosure box may be performedby using a fastener of a mechanism and a material other than the plasticflanged-tube fastener as described herein, as long as it can connect thesheet and box walls by being inserted into aligned openings from outsidethe enclosure box.

It is therefore to be understood that, within the scope of the appendedclaims, the disclosure of this patent specification may be practicedotherwise than as specifically described herein.

1. A packaging container used to package an article, the containercomprising: a pallet substantially rectangular in plan to carry thearticle thereon; the pallet including: a load carrying surface to carrythe packaged article thereon; and a hollow space below the load-carryingsurface having opposite side openings to allow entry of forklift tinesduring handling of the container; an enclosure box resting on the loadcarrying surface to enclose the article therewithin, the enclosure boxincluding: a top wall to cover a top of the article; first and secondpairs of opposite side walls extending downward from the top wall tocover sides of the article; an open bottom defined by edges of the sidewalls in contact with the load carrying surface to pass the articletherethrough during assembly; and a first set of through-holes definedin the first pair of side walls adjacent to the open bottom; anenclosure base lying between the article and the load carrying surfaceto hold the article within the enclosure box; a sheet extending acrossat least a portion of a lower side of the load carrying surface and thefirst pair of opposite side walls to secure the pallet to the enclosurebox when fastened to the enclosure box, the sheet including: a flatcenter panel that underlies the portion of the lower side of the loadcarrying surface; a pair of side flaps extending from opposite sides ofthe center panel upward along the first pair of opposite side wallsbeyond the first set of through-holes; and a second set of through-holesdefined in the pair of side flaps to align with the first set ofthrough-holes; and a set of fasteners passed through the first andsecond sets of through-holes to fasten the sheet to the enclosure boxfrom outside the enclosure box.
 2. The packaging container according toclaim 1, wherein the pallet includes multiple top deckboards extendingin a first direction with a gap therebetween to form the load-carryingsurface to carry the packaged article thereon, the first direction beingperpendicular to a second direction in which the forklift tines enterthe hollow space through the side openings of the pallet; the sheetinserted into the hollow space during assembly to locate the centerpanel beneath and across the load-carrying surface to cover the gapbetween the top deckboards.
 3. The packaging container according toclaim 1, wherein the pallet and the enclosure base at least partiallyinterlock with each other to restrict movement of the enclosure base onthe underlying pallet.
 4. The packaging container according to claim 1,wherein the sheet further includes a flap extending downward from thecenter panel to retain the sheet in place upon insertion into the hollowspace.
 5. The packaging container according to claim 1, wherein the setof fasteners are operated without using tools.
 6. A method for packagingan article in a container, the method comprising: providing a palletsubstantially rectangular in plan, the pallet including: a load carryingsurface to carry the packaged article thereon; and a hollow space belowthe load-carrying surface having opposite side openings to allow entryof forklift tines during handling of the container; providing anenclosure base on the load carrying surface; placing the article on theenclosure base; placing an enclosure box on the load carrying surface toenclose the article and the enclosure base therewithin, the enclosurebox including: a top wall to cover a top of the article; first andsecond pairs of opposite side walls extending downward from the top wallto cover sides of the article; an open bottom defined by edges of theside walls in contact with the load carrying surface to pass the articletherethrough; and a first set of through-holes defined in the first pairof side walls adjacent to the open bottom; placing a sheet across atleast a portion of a lower side of the load carrying surface and thefirst pair of opposite side walls, the sheet including: a flat centerpanel that underlies the portion of the lower side of the load carryingsurface; a pair of side flaps extending from opposite sides of thecenter panel upward along the first pair of opposite side walls beyondthe first set of through-holes; and a second set of through-holesdefined in the pair of side flaps to align with the first set ofthrough-holes; and fastening the sheet to the enclosure box from outsidethe enclosure box to secure the pallet to the enclosure box by passing aset of fasteners through the first and second sets of through-holes. 7.The packaging container according to claim 1, wherein the palletcomprises a triple-stringer pallet with a middle stringer and a pair ofend stringers extending parallel to each other to define a pair ofseparate hollow spaces below the load-carrying surface having oppositeside openings to allow entry of a forklift tine, and the sheet comprisesa pair of twin sheets each inserted into one of the separate hollowspaces to extend across at least the portion of the lower side of theload carrying surface and the first pair of opposite side walls tosecure the pallet to the enclosure box when fastened to the enclosurebox.
 8. The packaging container according to claim 2, further comprisinga spacer disposed within the gap defined between the top deckboards, thespacer and the top deckboards having a substantially equal thickness totogether form a substantially planar load carrying surface.
 9. Thepackaging container according to claim 4, wherein the flap has a heightslightly smaller than a height of the hollow space.
 10. The methodaccording to claim 6, wherein the pallet includes multiple topdeckboards extending in a first direction with a gap therebetween toform the load-carrying surface to carry the packaged article thereon,the first direction being perpendicular to a second direction in whichthe forklift tines enter the hollow space through the side openings ofthe pallet, and the sheet inserted into the hollow space during assemblyto locate the center panel beneath and across the load-carrying surfaceto cover the gap between the top deckboards.
 11. A packaging containerused to package an article, the container comprising: a palletsubstantially rectangular in plan to carry the article thereon, thepallet including: a plurality of top deckboards to carry and support thepackaged article thereon; and a hollow space below the plurality of topdeckboards to allow entry of forklift tines during handling of thecontainer; an enclosure box resting on the plurality of top deckboardsto enclose the article therewithin, the enclosure box including: a topwall to cover a top of the article; first and second pairs of oppositeside walls extending downward from the top wall to cover sides of thearticle; an open bottom defined by edges of the side walls in contactwith the plurality of top deckboards to pass the article therethroughduring assembly; and a first set of through-holes defined in the firstpair of side walls adjacent to the open bottom; an enclosure base lyingbetween the article and the plurality of top deckboards to hold thearticle within the enclosure box; a sheet extending across at least aportion of a lower side of the plurality of top deckboards and the firstpair of opposite side walls to secure the pallet to the enclosure boxwhen fastened to the enclosure box, the sheet including: a flat centerpanel that underlies the portion of the lower side of the plurality oftop deckboards; a pair of side flaps extending from opposite sides ofthe center panel upward along the first pair of opposite side wallsbeyond the first set of through-holes; and a second set of through-holesdefined in the pair of side flaps to align with the first set ofthrough-holes; and a set of fasteners passed through the first andsecond sets of through-holes to fasten the sheet to the enclosure boxfrom outside the enclosure box.
 12. The packaging container according toclaim 11, wherein the pallet includes: the plurality of top deckboardsextending in a first direction with a gap therebetween to form aload-carrying surface to carry the packaged article thereon, the firstdirection being perpendicular to a second direction in which theforklift tines enter the hollow space through the side openings of thepallet; and the sheet inserted into the hollow space during assembly tolocate the center panel beneath and across the load-carrying surface tocover the gap between the plurality of top deckboards.
 13. The packagingcontainer according to claim 11, wherein the pallet and the enclosurebase at least partially interlock with each other to restrict movementof the enclosure base on the underlying pallet.
 14. The packagingcontainer according to claim 11, wherein the sheet further includes aflap extending downward from the center panel to retain the sheet inplace upon insertion into the hollow space.
 15. The packaging containeraccording to claim 11, wherein the set of fasteners are operated withoutusing tools.